Umvelisi wezondlo zeenkukhu zaseSaudi ufumene i-98.2% yePDI ngeHongyang Ring Die kwi-+45°C

ISISHWANKATHELO sebhunga

Imveliso yenyama yenkukhu eSaudi Arabia ifikelele malunga ne-1.3 yezigidi zeetoni ngo-2024, ukwanda kwe-12.9% unyaka nonyaka okuqhutywa ngumyalelo wokhuseleko lokutya weVision 2030 ojolise kwi-80% yokuzimela kwenkukhu (GASTAT, 2024). Olu lwandiso lubeka iimfuno ezingaqhelekanga kubavelisi bokutya, ngakumbi kwiinyanga zasehlotyeni apho amaqondo obushushu ahlala edlula i-45°C. I-Al-Riyadh Feed Industries (igama elingachazwanga ngokwesicelo somthengi), enye yabavelisi benkukhu abahlanu abaphambili baseBukumkanini abanomveliso wokutya okuhlanganisiweyo wonyaka odlula iitoni ezingama-280,000, ijongene nomqobo omkhulu kwimveliso: ukuqina kwepellet kuye kwehla rhoqo ngexesha lobushushu phakathi kukaMeyi noSeptemba, kwehla ukuya kuthi ga kwi-91-92% yePDI (iPellet Durability Index) xa kuthelekiswa nomgangatho wangaphakathi wenkampani we-≥96%.

Phakathi kowama-2024, inkampani yalungisa imigca emibini ephambili ye-pellet mill ngee-ring die assemblies ze-Hongyang HYPM-series kunye nee-roller shells ezihambelanayo. Kwiintsuku zokuqala ezingama-90 zokusebenza ukuya kuthi ga kwihlobo eliphakamileyo, imigca ifumene i-PDI eqhubekayo ye-98.2% (± 0.5), yasusa iziganeko zokuminxa ezibangelwa bubushushu, kwaye yanciphisa i-ring die replacement frequency malunga ne-35% xa kuthelekiswa nee-dies ezazisetyenziswa ngaphambili eYurophu. Olu phononongo lwetyala luhlola imingeni yobugcisa ye-pelleting yobushushu obuphezulu, impendulo yobunjineli be-Hongyang, kunye neziphumo ezinokulinganiswa ezifunyenweyo.

Imvelaphi yoShishino kunye neyabathengi

ISaudi Arabia isebenza phantsi kwenye yezona ndawo zinzima kakhulu kwihlabathi jikelele zokuvelisa imfuyo ngamandla. IGunya eliPhezulu leeNkcukacha-manani libike ukuba iphondo laseRiyadh lodwa livelise iitoni ezingama-359,700 zenyama ye-broiler ngo-2024, kulandele iHail (iitoni ezingama-295,000) kunye neQassim (iitoni ezingama-200,000). Ukutya kumela i-60-70% yeendleko zemveliso ye-broiler iyonke, nto leyo eyenza umgangatho we-pellet ube ngumahluko omkhulu kwezoqoqosho.

I-Al-Riyadh Feed Industries isebenzisa iifektri ezintathu zokutya ezikummandla ophakathi zityisa iifama zeenkuku ezingama-42 eziqeshwe yinkampani. Ifomyula yabo ephambili yokugqiba iinkukhu yisiseko somgubo wesoya kunye nesoya enobubanzi bepellet obuyi-3.0 mm, ijolise kubushushu bepellet obugqityiweyo obungaphantsi kwama-88°C xa kuphuma i-cooler discharge. Ngaphambi kokulungiswa kweHongyang, inkampani yayisokola ngepateni yexesha eliphindaphindayo: njengoko ubushushu obuphakathi bunyuka budlula ama-38°C (ngesiqhelo ekuqaleni kukaMeyi), imithwalo yeemoto zepellet mill yaba yinto engaguqukiyo, ubushushu bomphezulu bunyuke ngaphezu kwama-95°C, kwaye i-PDI yepellet egqityiweyo yehla ngaphantsi komda wama-96% ofunekayo ukugcina amazinga amkelekileyo okuchitha ukutya kwinqanaba lefama.

Isiphumo sezoqoqosho besinokulinganiswa. Idatha yeshishini evela kwi-International Poultry Research Institute ibonisa ukuba ukuhla kwe-1% kwi-PDI nganye kuhambelana nokunyuka okuqikelelweyo kwe-0.4-0.6% kokulahlwa kokutya kwiinkqubo zokutya ezifakwe epanini — nto leyo ethetha ukuba malunga ne-1,100-1,700 yeetoni ezongezelelweyo zokutya ezilahlekayo minyaka le kwisikali sika-Al-Riyadh xa i-PDI incipha ngokwexesha lonyaka.

Umngeni: Ubushushu obugqithisileyo kunye nokuwohloka komgangatho wePellet

Ukucoca ukutya kweenkukhu kusebenza ngaphakathi kwefestile encinci ye-thermodynamic. Ubushushu obufanelekileyo bokulungisa i-mash buphakathi kwama-75-90°C, kwaye amaqondo obushushu okuphuma kwi-die agcinwa kuma-80-90°C. Ngaphezulu kwama-95°C, ukuchithwa kobushushu kweevithamini ezishushu (A, D, E, K) kunye nee-amino acids zokwenziwa (lysine, methionine) kukhawulezisa ngokulinganisela. Kwangaxeshanye, impendulo yeMaillard phakathi kokunciphisa iiswekile kunye nee-amino acids zasimahla iqala ukubopha i-lysine kwii-complexes ezingagayekiyo, inciphisa ngokufanelekileyo uxinano lwezondlo ezikhoyo (iJournal of Applied Poultry Research, 2019).

Kwimizi-mveliso ka-Al-Riyadh, ubushushu basehlotyeni bazise iindlela ezintathu zokungaphumeleli ezidityanisiweyo:

1. Ukungasebenzi kakuhle komthamo wokupholisa: Umoya ongaphakathi kwi-45°C unciphise i-thermal gradient yesibandisi esijikelezayo, nto leyo ethintela ii-pellets ukuba zingafikeleli kubushushu obufunekayo bokukhupha obuyi-5°C ngaphezu kwe-air. Ii-pellets eziphuma kubushushu obugqithisileyo zigcina umswakama oshiyekileyo kwaye zithambile ngexesha lokugcina.

2. Ukubaleka kobushushu obuphezulu: Xa iqondo lobushushu liphezulu ngama-45°C, amandla okukhupha ubushushu kwi-pellet mill agqithisiwe. Ubushushu bomphezulu we-die bunyuke ngaphaya kwama-95°C kwimizuzu yokuqala engama-45 yokusebenza ngokuqhubekayo, nto leyo eyabangela ukuvalwa ngokuzenzekelayo kwe-PLC yokhuseleko lwe-mill.

3. Ukutyibilika kweshelufu yerola: Amaqondo obushushu aphezulu anciphise i-coefficient esebenzayo yokungqubana phakathi komphezulu weshelufu yerola kunye ne-mash elungisiweyo, nto leyo ebangela ukutyibilika kwerola okungapheliyo, ukusasazwa kwezinto ezingalinganiyo kubuso berola, kunye neepateni zokunxiba zerola ezikwindawo ethile.

Isiphumo: i-pellet PDI yehle yaya kwi-91.2% (ilinganiswe ngendlela ye-ASAE S269.4 tumbling), inkcitho yokutya kwiifama yanda malunga ne-2.8%, kwaye isityalo sanyanzeleka ukuba sinciphise i-output nge-15-20% ngexesha leeyure ezishushu kakhulu ukuze kuthintelwe ukuvalwa. Ubomi benkonzo ye-ring die - esele icinezelwe ngumxholo we-silica kumbona ofumaneka apha ekhaya - yehle ukusuka kwi-avareji yeeyure zokusebenza ezingama-3,500 ebusika ukuya kwiiyure ezingama-2,200-2,500 ehlotyeni.

Hongyang Solution

Emva kophicotho-zincwadi lobuchwephesha olwenziwe ngokubambisana neqela lobunjineli bezicelo laseHongyang, kwenziwe uhlengahlengiso olunezigaba ezintathu kwimigca emibini yepellet mill:

1. I-Precision Ring Die ene-Optimized Compression Ratio

UHongyang ucacise i-ring die eyi-3.0 mm ububanzi enomlinganiselo wokucinezelwa we-1:12.5 — elungiselelwe ukwenziwa kwe-broiler finisher yomthengi (isiseko somgubo we-corn-soybean esinamafutha ongezelelweyo ayi-3.2% kunye ne-14.5% yomswakama we-post-conditioning target). Izinto ze-die yayiyi-X46Cr13 (DIN 1.4034 / Chinese 4Cr13) martensitic stainless steel, ecutshungulwa ngokuqiniswa kwe-vacuum kwi-1,050-1,080°C kulandele ukufuthwa kabini kwi-220-240°C ukuze kufunyanwe ubunzima obufanayo bomphezulu we-HRC 52-54 kuyo yonke i-die track.

Ngokubalulekileyo, ubuchwepheshe be-die hole obugqojwe ngemipu bukaHongyang — obusebenzisa i-CNC deep-hole drilling enokunyamezelana kwesimo se-±0.02 mm — buvelise ukufana kobubanzi be-hole-to-hole obulinganiswa kwi-≤15 μm variance. Eli nqanaba lokuchaneka linciphisa ukumelana nokuhamba komahluko kubuso be-die, into ebalulekileyo ekugcineni uxinano lwe-pellet oluhambelanayo phantsi kweemeko zobushushu eziguquguqukayo. I-die hole inlet nganye igqitywe nge-lead-in chamfer enciphileyo kwi-60° ukunciphisa ukumelana nokungena kwezinto, kunciphisa ngokufanelekileyo ukusetyenziswa kwamandla athile (kWh/ton) okufunekayo ukuqalisa ukwakheka kwe-pellet.

2. Indibano yeRoller Shell ehambelanayo enoBume obuphezulu bokuBearing Configuration

UHongyang unikezele ngeseti efanayo yee-roller shells ezenziwe ngentsimbi ye-alloy ye-20CrMnTi enobunzulu be-carburised case obuyi-2.0-2.2 mm kunye nobunzima bomphezulu be-HRC 60-62. Ipateni ye-corrugation yayiyilwe nge-groove pitch eyi-1.2 mm kunye nobunzulu be-groove obuyi-0.8 mm, elungiselelwe ukubamba izinto kakuhle kwi-broiler mash ene-friction ephantsi, enamafutha amaninzi.

I-roller assembly yayiquka ii-roller bearings ezitywiniweyo zobushushu obuphezulu (i-SKF Explorer-class equivalent, elinganiswe kwi-120°C continuous operating temperature), ithatha indawo yee-standard bearings ezazibonakalise ukuqhekeka kwegrisi kunye nokuqhekeka kwangaphambi kwexesha ngexesha lemveliso yasehlotyeni. I-labyrinth-style multi-stage seal ene-PTFE lip elements yathintela ukungena kwe-fines, i-common failure vector xa i-mash particulate eshushu neyomileyo ingena kwiindawo zee-bearing housings.

3. Iprotokholi yoLungiso lweDie-Roller Gap

Iqela lobuchwephesha likaHongyang liseke umsantsa we-die-roller we-0.40 mm (± 0.05 mm), olinganiswe ngokubanda nge-feeler gauge kwiindawo ezintandathu ezilinganayo ezijikeleze umda we-die. Olu luhlu lwemisantsa oluqinileyo kunoluqhelekileyo luhlawulela ukwanda kobushushu kubushushu bokusebenza: kubushushu bomphezulu we-die obuyi-85°C, i-X46Cr13 die iyanda nge-radially malunga ne-0.08-0.12 mm (i-coefficient yokwandiswa kobushushu ≈10.5 × 10⁻⁶/K), ivala ngempumelelo umsantsa wobushushu ukuya kwi-0.28-0.35 mm ephantse ibe yeyona ifanelekileyo kwiimeko zokusebenza. Le ndlela yangaphambi kokuhlawula ithintela umsantsa ukuba ungabi mkhulu kakhulu ngexesha lokuqhuba kwehlobo, nto leyo eya kunciphisa amandla oxinzelelo kwi-mash kwaye ibeke emngciphekweni uxinano lwe-pellet.

Idatha yeMveliso kunye neZiphumo

Idatha yokusebenza iqokelelwe kwixesha lovavanyo lweentsuku ezingama-90 (ngoJuni-Agasti 2025, ihlobo eliphakamileyo) kuzo zombini iimigca ezilungisiweyo, kunye nokusebenza kwehlobo elidlulileyo (ngoJuni-Agasti 2024) kusebenza njengesiseko.

| Ipharamitha | Isiseko (ihlobo lika-2024) | I-Hongyang Retrofit (ihlobo lika-2025) | Uphuculo |

| I-PDI ephakathi (ASAE S269.4) | 91.2% | 98.2% (± 0.5%) | +7.0 iipesenti zamanqaku |
| Ubushushu bomphezulu we-die (imeko ezinzileyo) | 94-98°C | 85-89°C | -9°C umyinge |
| Ubushushu bokukhupha iipellet (emva kokuphola) | 36-40°C | 29-33°C | -7°C umyinge |
| Ukuvalwa ngokuzenzekelayo okubangelwa bubushushu (ngenyanga) | Iziganeko ezi-8-12 | Iziganeko ezi-0 | Ukususwa ngokupheleleyo |
| Ukunciphisa umthamo ngexesha lobushushu obuphezulu (xa kuthelekiswa nobusika) | -18% | -3% | Ukubuyiselwa kwe-15% yamanqaku |
| Ubomi benkonzo ye-Ring die (eqikelelweyo, eqikelelweyo) | iiyure ezingama-2,200-2,500 | iiyure ezingama-3,400-3,800 (eqikelelweyo) | +52% eqikelelweyo |
| Ukusetyenziswa kwamandla athile (kWh/ton) | 18.7 | 17.2 | -8% |
| Ukulahlwa kokutya efama (% yokutya okuziswayo) | 4.8% | 1.9% | -60% ukuncitshiswa |
| Umthamo wesohlwayo xa kuziswa efama (<2 mm isihluzo) | 8.5% | 1.7% | -80% ukunciphisa |

Eyona nto ibalulekileyo ekuphuculweni kokusebenza yayikukususwa ngokupheleleyo kokuvalwa ngokuzenzekelayo okubangelwa bubushushu. Ngexesha lehlobo lika-2024, isiganeko ngasinye sokuvalwa sasifuna malunga nemizuzu engama-25-35 yexesha lokungasebenzi - kubandakanya ukucoca ngodaka, ukuqala kwakhona, kunye nokucoca izinto - okubangela ukuba ixesha lokuvelisa eliqikelelweyo libe ziiyure ezili-15-20 ngenyanga. Njengoko kungekho ziganeko zokuvalwa ezirekhodwe ngexesha lovavanyo luka-2025, ixesha lemveliso elifumanekayo linyuke malunga ne-8%.

Ukuphuculwa kokuqina kweepellet kuzise iingenelo zoqoqosho ezingaphantsi kolindelo. Ukuncipha komxholo wezohlwayo ekuhanjisweni kwefama ukusuka kwi-8.5% ukuya kwi-1.7% kuguqulelwe ngokuthe ngqo ekubeni kuncitshiswe ukutya kwiinkqubo zokutyisa ezizenzekelayo. Kwinqanaba lemveliso yomthengi leetoni ezingama-280,000 ngonyaka, oku kunciphisa kwama-60% kokuchithwa kwefama kubonisa uqikelelo lweetoni ezingama-8,100 zokutya ezigciniweyo ngonyaka - ezilingana ne-$2.8 yezigidi ngamaxabiso okutya kwengingqi (Ingxelo ye-USDA GAIN, umlinganiselo weendleko zokutya kweSaudi ka-2024).

Uvavanyo lwaBathengi

Umphathi wemveliso yezityalo unike olu vavanyo lulandelayo ngexesha lophononongo lwasemva kovavanyo:

I-Hongyang ring die kunye ne-roller assembly isebenze ngaphaya kweenkcukacha zethu zobugcisa. Inkxalabo yethu ephambili xa singena ehlotyeni yayikukuba ingaba nayiphi na i-ring die — nokuba ivela phi — inokugcina umgangatho we-pellet ohambelanayo xa umoya ojikeleze umoya ungena kwindawo epholileyo elinganiswe ngaphezu kwama-45°C. I-98.2% PDI esiyifumeneyo ayidlulanga nje kuphela usukelo lwethu lwasehlotyeni lwama-96% kodwa ihambelana okanye idlule isiseko sethu sasebusika. Ukususwa kwe-die-related closures kuphela kwenze ukuba utyalo-mali lube sesikweni. Ukunciphisa ukusetyenziswa kwamandla athile kwakuyibhonasi engalindelekanga.
— Umphathi weMveliso, i-Al-Riyadh Feed Industries (iCentral Region Mill)

Umlawuli wokuthenga wenkampani ukongeza wathi amaxabiso e-ring die kaHongyang ayengaphantsi kwama-35% kunalawo athengiswa ngaphambili eYurophu, ngelixa efikelela kubomi benkonzo obulinganayo okanye obuphezulu phantsi kweemeko zasehlotyeni zaseSaudi. Isiphumo esidibeneyo - ubomi be-die obude, iindleko zokuthenga eziphantsi, ukusetyenziswa kwamandla okuncitshisiweyo, kunye nomgangatho ophezulu we-pellet - sivelise imbuyekezo ebaliweyo kutyalo-mali ngaphakathi kweenyanga ezi-7.5.

Isiphelo

Ityala lika-Al-Riyadh libonisa ukuba ubuchwepheshe be-ring die obucwangciswe ngokuchanekileyo obuvela eHongyang bunokuhlangabezana neemfuno ezifunekayo zokuveliswa kokutya kweenkuku ezishushu kakhulu kummandla weGulf. Izinto ezintathu zobugcisa zibe negalelo kwisiphumo:

1. Ukusetyenziswa kwesayensi yezinto eziphathekayo: I-alloy ye-X46Cr13 eqinileyo kwi-vacuum kwi-HRC 52-54 ene-CNC gun-drilled hole efanayo imele umgangatho wesilingi onokufikelelwa kwii-broiler feed ring dies kumanqanaba obuchwepheshe be-metallurgical angoku.

2. Ukulinganiswa kwesithuba esiqaphela ubushushu: Ukuhlawula kwangaphambili isithuba esibandayo se-die-roller ukuze kwandiswe ubushushu kubushushu bokusebenza yindlela engabizi kakhulu, enefuthe elikhulu ekufuneka ilandelwe ziifektri zokutya kwiindawo ezishushu njengenkqubo yokusebenza eqhelekileyo.

3. Ukuhlanganiswa kwenkqubo ehambelanayo: I-ring die, i-roller shell, kunye noqwalaselo lweebheari zenziwe njengenkqubo yolawulo lobushushu edibeneyo kunokuba zibe ziinxalenye ezizimeleyo - indlela eyahlula izisombululo ezicwangciswe yi-application kwi-commodity die supply.

Kubavelisi bezondlo abasebenza kuMbindi Mpuma, eMntla Afrika, nakwezinye iindawo ezinobushushu obuphezulu, iziphumo ze-Al-Riyadh zibonelela ngomlinganiselo obalulekileyo: i-98.2% ye-PDI engenazo izivalo ezibangelwa bubushushu inokufezekiswa kwinqanaba lorhwebo ngetekhnoloji ye-ring die echazwe ngokuchanekileyo.

Imithombo yedatha: I-GASTAT Livestock Statistics 2024; I-IMARC Group Saudi Arabia Compound Feed Market Report 2024; I-USDA GAIN Report SA2024-0002; Ijenali yoPhando lweeNkukhu eziSetyenzisiweyo (2019) uMqulu 28, Ingxaki 4; I-ASAE Standard S269.4; Idatha yobunjineli bezicelo zangaphakathi zaseHongyang, ixesha lovavanyo lukaJuni-Agasti 2025.